Air flow regulation in granular material delivery system

ABSTRACT

Methods for conveying granular material from a supply to receivers that retain and dispense the material when needed by process machine include a vacuum pump, an air flow regulator connected to the vacuum pump, a first conduit connecting the receivers to the air flow regulator, and a second conduit connecting the material supply to the receivers.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This patent application is a 35 USC 120 division of U.S. Ser. No.15/392,650, entitled “Granular Material Delivery System with Air FlowLimiter”, filed 28 Dec. 2016 in the names of Stephen B. Maguire andJames Zinski, published as US 2017/0107064, now allowed, the priority ofwhich Applicant claims under 35 USC 120.

The '650 patent application was a continuation-in-part of U.S. Ser. No.14/574,561, entitled “Resin Delivery System with Air Flow Regulator”,filed 18 Dec. 2014 in the names of Stephen B. Maguire and James Zinski,published 20 Aug. 2015 as US 2016-0238016 A1, issued 28 Mar. 2017 asU.S. Pat. No. 9,604,793, the priority of which Applicant claims under 35USC 120 through the '650 application.

The '561 application was in turn a continuation-in-part of U.S. Ser. No.14/185,016, entitled “Air Flow Regulator”, filed 20 Feb. 2014 in thename of Stephen B. Maguire, published 20 Aug. 2015 as US 2015/0232287 A1and issued as U.S. Pat. No. 9,371,198 on 21 Jun. 2016, the priority ofwhich Applicant also claims under 35 USC 120 through the '561 and '650applications.

The '650 patent application was also a 35 USC 120 continuation-in-partof U.S. Ser. No. 14/602,784 entitled “Method and Apparatus for ResinDelivery with Adjustable Air Flow Limiter” filed 22 Jan. 2015 in thename of Stephen B. Maguire, published 20 Aug. 2015 as US 2015-0232290A1, issued as U.S. Pat. No. 9,555,636 on 24 Jan. 2017, the priority ofwhich Applicant claims under 35 USC 120 through the '650 application.

The '650 patent application was also a 35 USC 120 continuation-in-partof pending U.S. Ser. No. 14/804,404 entitled “Vacuum Powered ResinLoading System Without Central Control” filed 21 Jul. 2015 in the nameof Stephen B. Maguire, published 12 Nov. 2015 as US 2015-0321860 A1, thepriority of which Applicant claims under 35 USC 120 through the '650application.

The '650 patent application was also a 35 USC 120 continuation-in-partof U.S. Ser. No. 14/593,010 entitled “Air Flow Limiter with Closed/OpenSensing”, filed 9 Jan. 2015 in the name of Stephen B. Maguire, published20 Aug. 2015 as US 2015-0232289 A1, issued as U.S. Pat. No. 9,550,635 on24 Jan. 2017, the priority of which Applicant claims under 35 USC 120through the '650 application.

The '650 application also claimed, under 35 USC 120, through the '404,'561 and '016 applications, the benefit of the priority of U.S.provisional application Ser. No. 62/027,379 entitled “Central VacuumLoading System Without Central Control”, filed 22 Jul. 2014 in the nameof Stephen B. Maguire; Applicant similarly claims the benefit thepriority of the '379 application under 35 USC 120 through the '404,'650, '561 and '016 applications.

This patent application is also a 35 USC 120 continuation-in-part of andclaims the benefit of the priority of pending U.S. patent applicationSer. No. 15/470,065 filed 27 Mar. 2016 in the name of Stephen B.Maguire, entitled “Self-Controlled Vacuum Powered Granular MaterialConveying and loading System and Method”, published 3 Aug. 2017 as US2017/0217694 A1.

This patent application is also a 35 USC 120 continuation-in-part of andclaims the benefit of the priority of pending U.S. patent applicationSer. No. 15/918,161 filed 12 Mar. 2018 in the name of Stephen B.Maguire, entitled “Vacuum Powered Self-Controlled Loading and ConveyingGranular Material”, published 19 Jul. 2018 as US 2018/0201453 A1.

This patent application is also a 35 USC continuation-in-part and claimsthe benefit of the priority of pending U.S. patent application Ser. No.15/827,724 filed 30 Nov. 2017 in the name of Stephen B. Maguire,entitled “Method for Low Profile Receiver Operation” published 22 Mar.2018 as US 2018/0079603 A1.

The '724 application was a division of application Ser. No. 15/012,001filed 1 Feb. 2016 in the name of Stephen B. Maguire, entitled “LowProfile Receiver”, published 6 Jul. 2017 as US 2017/0190518 A1, issued21 Aug. 2018 as U.S. Pat. No. 10,053,303. Applicant claims the benefitof the priority of the '001 application under 35 USC 120 through the'724 application.

This patent application is also a 35 USC 120 continuation-in-part andclaims the benefit of the priority of pending U.S. patent applicationSer. No. 15/457,051 filed 13 Mar. 2017 in the name of Stephen B.Maguire, entitled “Resin Dryer Control by Regulation of Hot Air VolumeSupply Rate”, published 14 Sep. 2017 as US 2017/0261261.

Under 35 USC 120 the '051 application claimed the priority of U.S.provisional application Ser. No. 62/307,945, filed 14 Mar. 2016 in thename of Stephen B. Maguire and entitled “Resin Dryer Control byDeregulation of Hot Air Supply Rate”. Applicant claims the benefit ofthe priority of the '945 application under 35 USC 120 though the '051application.

This patent application is also a 35 USC 120 continuation-in-part andclaims the benefit of the priority of pending, now allowed, U.S. patentapplication Ser. No. 15/293,409, filed 14 Oct. 2016 in the name ofStephen B. Maguire, entitled “Tower Configuration Gravimetric Blender”,published 12 Apr. 2018 as US 2018/0099253 A1.

The '409 application is a continuation-in-part of United States designpatent application 29/580,163, filed 6 Oct. 2016 in the name of StephenB. Maguire, entitled “Tower Configuration Gravimetric Blender”, issued 9Jan. 2018 as United States design patent D807,414. Applicant claims thebenefit of the priority of the '163 application under 35 USC 120,through the '409 application.

INCORPORATION BY REFERENCE

The disclosures of the aforementioned published United States patentapplications and the aforementioned United States patents are herebyincorporated by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT

Not Applicable.

BACKGROUND OF THE INVENTION Field of Invention

This invention relates principally to manufacture of plastic articlesand even more particularly relates to pneumatic conveyance andprocessing of plastic resin pellets, as well as other granularmaterials, prior to molding, extrusion, or other processing of thosepellets or other granular materials into a finished or semi-finishedproduct.

In this patent application, injection and compression molding pressesand extruders are collectively referred to as “process machines.”

Description of the Prior Art

Current resin and other granular material central loading systemsconcerned with conveying granular material from a storage area formolding or extrusion typically include a vacuum pump or pumps andmultiple receivers.

In some systems, with many receivers, several small pumps are used.

It would be less expensive to use only one, or fewer, larger pumps.However, a larger pump may draw too much air with resulting damage tothe material being conveyed. While a larger pump could load severalreceivers at once, there is a risk that an “open” line, namely a linedrawing only air, and no material, would cause the vacuum to drop toomuch, and no material would load. Also, when only one receiver isloading material, air velocity might be too high, again with a risk ofdamaging the material.

Nevertheless, in facilities that fabricate products by molding orextrusion, it is common to use such vacuum loading systems topneumatically convey pellets of thermoplastic resin or other materials,prior to molding, extrusion, or other processing of those pellets orother materials into a finished or semi-finished product. The materialsare typically purchased in 50 pound bags, 200 pound drums, or 1,000pound containers commonly referred to as “Gaylords.”

A preferred approach for conveying plastic resin pellets and othergranular materials from a storage location to a process machine, whichapproach is often used in larger facilities, is to install a centralvacuum pump or even several vacuum pumps, connected by common vacuumlines to multiple “receivers.”

Vacuum pumps connected to the vacuum lines draw vacuum, namely air atpressure slightly below atmospheric, as the vacuum pump sucks airthrough the “vacuum” line. The suction moves large quantities of airwhich carries thermoplastic resin pellets or other granular materialthrough the “vacuum” line.

An alternative is to use positive pressure produced by either a bloweror the exhaust side of a vacuum pump. With such an approach, thepositive pressure results in movement of substantial amounts of airwhich may be used to carry the granular material. However, the vacuumapproach of drawing or sucking granular material through the systemconduits is preferable to the positive pressure approach of pushing thematerial granules through the system conduits.

In practice, vacuum pumps are preferred and vacuum lines are desirablein part because power requirements to create the required vacuumnecessary to draw granular materials through the lines are lower thanthe power requirements if the material granules are pushed through thelines by a blower or by the exhaust side of a vacuum pump. When vacuumis used, the static pressure within the line may be not much less thanatmospheric. When positive pressure is used, the dynamic pressure of theair flowing through the line must be relatively high in order to move anadequate quantity of granular material.

As used herein, and in light of the foregoing explanation, the terms“vacuum pump” and “blower” are used interchangeably.

When one or more central vacuum pumps are connected to multiplereceivers, a receiver is typically located over each temporary storagehopper, in which the plastic resin pellets or other granular material istemporarily stored before being molded, extruded, or otherwiseprocessed. A temporary storage hopper is typically associated with eachprocess machine.

In current practice, the receiver is connected by a control wire to acentral control system. The control system works by selectively openinga vacuum valve located in each receiver, allowing one or several vacuumpumps to work in sequence drawing “vacuum”, i.e. below atmosphericpressure air, to carry the pellets or other material granules among andto multiple receivers as individual ones of the receivers, positionedover individual hoppers associated with the individual process machines,require additional plastic resin pellets or granules of other material.The receiver for a given hopper-process machine combination is actuatedby opening the vacuum valve located in or near the receiver, causing thereceiver to supply plastic resin pellets or granules of other materialby gravity feed into the hopper from where the pellets or other materialgranules may be fed further downwardly by gravity into the associatedprocess machine.

Large, high capacity industrial vacuum pumps are reliable and are suitedto heavy duty industrial use. Large high capacity vacuum pumps allowlong conveying distances for the plastic resin pellets and othergranular materials. Currently available large capacity vacuum pumpspermit plastic resin pellets and other granular materials that aresimilar in size and density to be conveyed over distances of 200 feet ormore using vacuum drawn by the pump. Use of such high capacity vacuumpumps results in a rush of below atmospheric pressure air through theline, carrying the plastic resin pellets or other granular materialsover a long distance.

Operators of manufacturing facilities prefer to buy plastic resinpellets and other necessary granular materials in bulk, in rail cars ortanker trucks. Bulk purchases result in cost savings. Such materialsdelivered in bulk are typically pumped into large silos for storage. Ina large manufacturing facility, the distance from a plastic resin pelletor other material storage silo to a process machine may be severalhundred feet, or more. Accordingly, when plastic resin pellets or othergranular materials are purchased in bulk, a central vacuum-poweredconveying system, powered by one or more large, high capacity industrialvacuum pumps, is a necessity.

Typically, large central plastic resin pellet and other similar granularmaterial conveying systems have one or more vacuum pumps, each typicallyfrom 5 to 20 horsepower. These central systems include central controlsconnected by wire to each receiver associated with each process machinein the facility. Typically eight, sixteen, thirty-two or sixty-fourreceivers, each associated with a process machine, may be connected toand served by the central vacuum conveying system. Of course, the higherthe number of receivers served by the system, the higher the cost.

A factor to be considered in designing such a system is the speed of theplastic resin pellets or other material granules as they flow through aconduit as the pellets or granules are carried by the moving air streamdrawn by the vacuum pump. If air flow is too slow, the pellets or othergranules fall out of the air stream and rest on the bottom of theconduit, with resulting risk of clogging the conduit. If air flow is toofast, the pellets or other granules can skid along the conduit surface.In such case, harder, more brittle plastic resin pellets and othergranular materials may be damaged, resulting in dust within the conduit,which when drawn into the vacuum pump can damage the vacuum pump andrender the system inoperative. Softer plastic resin pellets and othersoft granular materials heat up and can melt from friction whencontacting the conduit interior surface. In the case of plastic resinpellets, this results in “angel hair”—long, wispy-thin strands ofplastic film which eventually clog the conduit and cause the system toshut down.

For these reasons, pneumatic plastic resin pellets and other granularmaterial conveying systems must be designed to produce desired,reasonable conveying speeds for the conveyed materials.

Currently, conveying speed of the plastic resin pellets and othergranular material is most often controlled by controlling air flow,measured in cubic feet per minute, and varying the desired and designedcubic feet per minute based on conduit diameter, with a larger diameterconduit requiring more cubic feet per minute of air flow to maintainproper air flow speed through the conduit. Controlling air flow,measured in cubic feet per minute, is conventionally done by properlyspecifying the vacuum pump by capacity and, in some cases, by varyingspeed of the vacuum pump as the vacuum pump draws the air in a “vacuum”condition through the conduit, carrying plastic resin pellets or othermaterial granules in the moving, below atmospheric pressure air.Controlling cubic feet per minute of air flow is an indirect way ofcontrolling plastic resin pellet or other material granule speed as thepellets or other granules flow through a conduit of a given diameter.

Typically, a 2 inch diameter conduit requires about 60 cubic feet perminute of air flow to convey typical plastic resin pellets or othergranular material of similar size and density characteristics. A 2½ inchdiameter conduit typically requires about 100 cubic feet per minute ofair flow to convey typical plastic resin pellets or other granularmaterial. To achieve these desired air volume flow rates, a conventionaldesigner must carefully match the horsepower of a vacuum pump, which hasa given cubic feet of air per minute rating, to a selected size conduit,taking into consideration the average distance the plastic resin pelletsor other material granules must be conveyed through the conduit from astorage silo to a receiver or loader. If this results in selection of a5 horsepower blower/vacuum pump, then a given facility may requireseveral such blowers/vacuum pumps, with each blower/vacuum pumpsupplying only a selected number of receivers.

A single plastic resin molding or extruding facility or another type ofgranular material processing facility might theoretically require a 20horsepower blower and the corresponding cubic feet per minute capabilityfor conveyance provided by the single blower to meet the total conveyingrequirements for plastic resin pellets or other material granulesthroughout the facility. However, a single twenty horsepower blowerwould result in far too high a conveying speed for the plastic resinpellets or other material granules through any reasonable size conduit.As a result, the conveying system for the plastic resin pellets or othergranular material in a large facility is necessarily divided and poweredby three or four smaller blowers, resulting in three or four different,separate systems for conveyance of plastic resin pellets or othergranular material. Sometimes several blowers are connected to a singleset of receivers, with one or more of the extra blowers turning “on”only when required to furnish the required extra cubic feet per minuteof air flow. This is controlled by a central station monitoring allreceivers and all blowers, with the central station being programmed tomaintain all of the hoppers associated with the process machines in afull condition, wherever those hoppers are located throughout thefacility.

Even with careful planning and design, results achieved by suchpneumatic plastic resin pellet or other granular material conveyingsystems are not consistent. Air flow speed and cubic feet per minutecapacity of blowers often vary and are outside of selected design andspecification values.

SUMMARY OF THE INVENTION

The instant invention provides an improvement to known pneumatic plasticresin pellet and other granular material conveying systems, reducing thecosts of those systems while providing consistent control of deliveredcubic feet per minute of air for individual receivers. The inventionalso facilitates easy expansion of the pneumatic plastic resin pelletand other granular material conveying system as the system grows. Suchexpandable systems are made feasible by an air flow controller embodyingaspects of this invention.

In one aspect of this invention, air flow control regulators, desirablyof the type generally disclosed in U.S. Pat. No. 9,371,198, are added toeach receiver so that the air pulled from any single receiver is limitedto the correct predetermined, preselected flow rate. This preventsexcessive flow rates and “open” lines that dump too much air into thesystem.

Use of these air flow regulators allow one large pump to be used withoutrisk to the system or to the resin or other granules being conveyed. Anadded advantage of a very large pump is that it can fill multiplereceivers simultaneously with resin or other granular material. As usedherein, the term “receiver” denotes the type of apparatus disclosed inU.S. Pat. Nos. 6,089,794; 7,066,689, and 8,753,432. The disclosures ofthese patents are hereby incorporated by reference.

The invention allows receivers to “load” the resin or other granularmaterial the instant there is demand for material by dropping orotherwise supplying the material, usually downwardly, into a gravimetricblender or directly into a process machine. The receiver need not waitin the “queue” to load because no sequencing of the receivers isrequired. Each receiver is always “ready to go.”

A central control station is not required, and neither is wiring fromeach receiver to a central control station, thus further reducing costs.

Consequently, in this invention as implemented in one of itsembodiments, there are one or several large vacuum pumps, with receiversthat stand alone without need for a central control, and an air flowregulator on each receiver to assure proper and constant flow rate.

This invention facilitates periodically reducing the speed of the vacuumpump, to hold the desired vacuum level in the lines. This is in contrastto running the vacuum pump at full speed all the time.

“CFM” is a term referring to a cubic foot of air regardless of thedensity of the air. “SCFM” refers to a cubic foot of air at standardtemperature and pressure, namely 70° F. at sea level. The air flowregulator holds SCFM constant. This means that air flow through the airflow regulator will be faster when the air is thin, such as at highaltitudes, and slower when the air is thick, such as at sea-level.However, in both cases (or any case), the air flow regulator maintainsSCFM, namely air flow in standard cubic feet per minute, constant.Stated differently, so long as the SCFM is held steady, as is the casewith the air flow regulator disclosed herein, the same weight of air, ornumber of air molecules, flows through the regulator regardless ofconditions. Air flow rate through the regulator may change in terms ofthe speed of the air, but in all cases, the quantity of air flowing,measured in standard cubic feet per minute, is constant.

In another embodiment of the invention one air flow regulator, asdisclosed in the instant application, is in place as a single air flowregulator at the vacuum pump suction inlet with the vacuum pump beingconnected to a plurality of receivers all connected in a system. Thisprovides a selected, correct rate of air flow in standard cubic feet perminute. In this embodiment of the invention, only a single air flowregulator is used at the vacuum pump inlet, as opposed to thealternative embodiment of the invention described above where one airflow regulator is used at each receiver.

An advantage of using only a single air flow regulator of the typedisclosed herein is that the vacuum pump can be sized and operated forthe longest distance over which resin or other granular material is tobe conveyed in a given locale. This can be done while still protectingshorter runs of the system from excessive granular material velocity,where less vacuum is required. One air flow regulator costs less thanhaving an air flow regulator located at every receiver; this provides anadvantageous aspect to this embodiment of the invention.

By adding an air flow regulator manifesting aspects of this invention toevery receiver, control of air flow in cubic feet per minute can bemaintained at a constant value that is ideal for that particularreceiver, considering conduit diameter and distance over which theplastic resin pellets or other granular material must be conveyedthrough the associated conduit. Alternatively, by adding an air flowregulator just to the suction inlet of the vacuum pump, one can controlair flow in cubic feet per minute to a constant value that is ideal forthe system as a whole, considering conduit diameter and distance overwhich the plastic resin pellets or other granular material must beconveyed to the multiple receivers in the system.

Use of the air flow regulator allows pneumatic plastic resin pellet orother granular material conveying systems to utilize a single large highhorsepower vacuum pump. In accordance with one embodiment of theinvention, each receiver in a facility is fitted with an air flowregulator embodying the invention so the flow for each receiver in cubicfeet per minute is self-limiting. This approach eliminates the need tomatch vacuum pumps or blowers to a specific material conduit size orconveyance distance. Using this approach, the flow regulator permitsoperators to run a very large vacuum pump or blower at a speed that willmaintain a desired high level of vacuum throughout the entire vacuum (orpneumatic) plastic resin pellet or other granular material conveyingsystem.

Using larger than standard diameter vacuum conduits allows a significantvacuum reserve to exist in the plastic resin pellet or other granularmaterial conveying system, without the need for a vacuum reserve tank.Larger diameter conduits also mean there is little loss of vacuum overlong distances, even at the most distant receiver to which plastic resinpellets or other material granules are supplied by the system. Avariable frequency drive control may be used to adjust the speed of thevacuum pump to maintain air flow at the desired standard cubic feet perminute rate through the air flow regulator.

With the flow regulator facilitating use of high horsepower vacuum pumpsor blowers, designers can now design to load multiple receivers at thesame time without fear of dropping vacuum levels too low in portions ofthe pneumatic or vacuum plastic resin pellet or other granular materialconveying system.

In the plastic resin pellet or other granular material conveying systemaspect of the invention, no central control system is required. Usingthe flow regulator of the invention, each receiver controls its ownoperation and is not wired to any central control facility. When thelevel of plastic resin pellets or other material granules in the hopperof a process machine falls to a sufficiently low level, a level sensortells the receiver to load the hopper of the process machine. Coupled tothe level sensor may be a vacuum sensor, which confirms that the mainsystem has sufficient vacuum available to load the receiver. If too manyother receivers are currently loading, and the vacuum level is sensed tobe below the threshold for effective loading, then the receiverassociated with the sensor will wait until vacuum readings rise. Whenavailable system vacuum is sufficient to assure adequate flow of plasticresin pellets or other material granules into a given receiver, thevacuum sensor causes a vacuum valve associated with the receiver to openthe connection of the receiver to the conduit carrying the plastic resinpellets or other granular material, and the receiver fills with resinpellets.

In accordance with one aspect of the invention, each receiver acts onits own sensed information. Use of the high horsepower vacuum pump meansthat several receivers can load simultaneously.

The air flow regulator does several things to make such systems inaccordance with the invention possible. By limiting cubic feet perminute of flow to the desired constant level, there is virtually nolimit on the horsepower of the vacuum pump. The risk of a too high aconveyance speed of the plastic resin pellets or other material granulesthrough the conduit is eliminated. Additionally, if a receiver is notdrawing in plastic resin pellets or other granular material but is justdrawing air as a result of the main supply of plastic resin pellets orother material granules being exhausted, the empty conduit of theconveying system would ordinarily convey a substantial amount of air,which normally would drop the vacuum reserve of the entire pneumaticconveying system very rapidly. But with the flow regulator such dumpingof air into the conveying conduit is at least substantially reduced, andif the flow regulator is at the suction intake of the vacuum pump, suchdumping of air into the system is essentially impossible.

Further contributing to minimized air dump into the vacuum conduit isthe receiver's ability to detect system failure or absence of materialbeing loaded, thereby stopping further load cycles and sounding analarm.

The air flow regulator preferably has but a single moving part, a valve,which relies on two opposing forces, namely gravity in one direction and“lift” created by air flow in the opposite direction. Because the airflow regulator uses gravity to close the valve portion of the regulator,orientation of the air flow regulator is important. Air flow must beupward, essentially or at least largely vertically through the air flowregulator, to counter the downward force of gravity.

The air flow regulator is desirably in the form of a tube with an airflow actuated valve within the tube. In a “no flow” condition, gravityholds the valve closed. However, as air flow through the regulatorreaches a pre-selected design value, air flowing over and against asail-like plate lifts an internal free floating valve. This shuts offair flow through the air flow regulator if the free floating valve risessufficiently to contact a stop located within the tube.

By adjusting the size and/or shape of the “sail”, and the weight of thefree floating valve, desired air flow in standard feet per minute can beregulated very closely. Gravity as a force in one direction means theopening force is constant over the full range of motion of the valvedevice. (A spring, if one were used, would provide a variable force.However, use of gravity in the air flow regulator eliminates thatvariable).

In the air flow regulator, at the desired design standard cubic feet perminute of air flow, the valve opens as air lifts it. The valve wouldcontinue moving upwardly except for the fact that the valve reaches apoint of air flow restriction where the valve holds air flow steady atthe desired design value. If the valve moves further upwardly towards a“closed” position, this reduces air flow and the resulting force on thevalve, causing the valve to drop in response to gravity. If the valvedrops below the control level, this allows more air flow andconsequently the valve rises as the air pushes the valve upwardly. As aresult, the valve reaches the desired design valve equilibrium controlpoint essentially instantly and very accurately. Usually the length ofthe short tube is less than the diameter of the short tube. Desirablythe length of travel of the short tube is no more than one half thelength of the short tube.

Known air flow shutoffs are subject to “vacuum pull”, causing them toshut off completely once air begins to flow. This is because in knownshutoffs, vacuum “pull” of the vacuum pump is always present. In the airflow regulator preferably used herein, a short vertical tube closesagainst a flat horizontal surface. In this air flow regulator, air flowis preferably directed through the center of the short tube andpreferably escapes over the top edge of the short tube and preferablythen around open edges of a flat shutoff surface. A flat, desirablytriangular or star-shaped plate is preferably positioned in the air flowbelow and preferably connected to the short tube. This plate acts as asail in the air flow and will, at the designed desired standard cubicfeet per minute air flow rate, provide enough lift to raise the shorttube against the shutoff plate.

At shut off, with vacuum above the flat shutoff surface and air at somepressure below the flat shutoff surface, most of the air pressure forcesare against the walls of the short tube. Those forces are radiallyoutwardly directed. Specifically, they are horizontal due to theconfiguration of the air flow regulator, and do not exert significantvertical force that would make the movable portion of the valve, namelythe short tube, move in a vertical direction.

The surface of the end of the short tube, at the short tube end edge, isa horizontal surface and can provide a small vertical force when airtravelling upwards impinges on the surface. For this reason, the airflow regulator aspect of the invention uses a very thin wall short tube,to minimize the vertically projected, horizontal surface area of theshort tube.

In the air flow regulator preferably used herein, air flow rate in cubicfeet per minute can be adjusted by adding or subtracting weight from thefloating valve, or by adjusting the surface area of the sail, or byadjusting the size or shape of the sail in the air flow.

Accordingly, in one of its aspects, the invention provides a resindelivery system and method that includes an air flow regulatorpreferably having a vertically oriented tube, a pair of open-endedtelescoping tubular internal segments within the tube, with an outertubular segment preferably being fixed and the other preferably beingslidably moveable along the fixed segment in the axial direction. Theair flow regulator preferably further includes a plate extendingpartially across the interior of the vertically oriented tube andpositioned for contacting the moveable one of the desirably telescopingtubular segments and limiting travel of the moveable telescoping tubularsegment, with the plate covering the upper, open end of the moveabledesirably telescoping tubular segment upon contact therewith. In thisaspect, the invention yet further preferably includes a sail positionedin the vertically oriented tube below the telescoping segments, a strutconnecting the sail and the moveable telescoping tubular segment, and abaffle positioned to direct upward air flow within the tube through thedesirably telescoping tubular segments. The moveable desirablytelescoping tubular segment moves vertically within the tube, unitarilywith the sail, responsively to air flowing upwardly through the tubeagainst the sail.

The tubular segments are preferably cylindrical; the surface of theplate contacted by the moveable tubular segment is preferably planar;and the portion of the moveable tubular segment contacting the platesurface is preferably annular.

In a variation of terminology, a surface of the plate contacted by themoveable tubular segment is flat, the tubular segments are cylindricaland the circular edge of the tubular segment contacting the platesurface is annular and normal to the axis of the tubular segment.

In yet another one of its aspects, this invention provides a granularmaterial delivery system having at least one air flow regulatorconsisting of a vertically oriented tube, a tubular segment within thetube, which segment is moveable in the axial direction, a plateextending at least partially across the interior of the tube forcontacting the movable tubular segment and defining a limit of travel ofthe moveable tubular segment, a sail positioned in the tube below themoveable tubular segment and being moveable vertically within the tube,a strut connecting the tubular segment and the sail, and a baffleconnected to and located within the tube defining a lower limit oftravel of the moveable tubular segment upon contact of the strut with anupper extremity of the baffle. The moveable tubular segment is insliding, desirably telescoping engagement with the tubular portion ofthe baffle, directing upward air flow within the tube, with the moveabletubular segment being moveable unitarily with the sail in response toupward air flow through the tube contacting the sail.

In yet another one of its aspects, this invention provides a granularmaterial delivery system that includes at least one air flow regulatorhaving a vertically oriented tube with a sail assembly positioned in thetube and moveable therewithin responsively to air flow through the tubeto regulate air flow through the tube and to stop air flow thorough thetube upon air flow exceeding a preselected value expressed in standardcubic feet per minute.

In yet another one of its aspects, this invention provides a method forconveying granular plastic resin or other granular material bycontrolled air flow where air flow control involves the steps ofproviding a vertically oriented tube, positioning a moveable sailassembly including a sail within the tube, positioning a stop within thetube, and permitting the sail assembly to move responsively to air flowthrough the tube between a position at which air flows around the sailassembly and through the tube, and a position at which the sail assemblycontacts the stop and blocks air flow through the tube.

In yet another one of its aspects, this invention provides a pneumaticgranular material delivery system utilizing air flow regulatingapparatus including a preferably substantially vertically oriented firsttube, a preferably substantially vertically oriented second tube whichis moveable along and within the first tube, a baffle within the firsttube for forcing air flow in the first tube through the second tube, aguide within the first tube for limiting the second tube to preferablysubstantially vertical co-axial movement within and relative to thefirst tube, a sail within the first tube being connected to the secondtube and being moveable responsively to air flow within the first tube,and a stop within and connected to the first tube for limiting upwardtravel of the second tube.

In still another one of its aspects, this invention provides apparatusfor conveying granular plastic resin or other granular material from asupply preferably to receivers that retain and dispense the resin orother material granules when needed by a process machine, where theapparatus preferably includes a vacuum pump, a single air flow regulatorpreferably connected to a suction head of the vacuum pump, a firstconduit preferably connecting the receivers to the air flow regulator,and a second conduit preferably connecting the granular material supplyto the receivers. In this embodiment of apparatus of the invention,suction created by operation of the vacuum pump preferably drawsgranular plastic resin or other material granules from the supply intothe receivers through the second conduit and preferably draws air fromthe second conduit through the receivers, the first conduit and the airflow regulator. The air flow regulator is preferably orientedsubstantially in a vertical direction for substantially vertical flow ofair substantially upwardly therethrough.

In yet still another aspect, this invention provides apparatus forconveying granular plastic resin material or other granular materialfrom a supply of granular material to receivers that retain and dispensethe resin or other granular material when needed by a process machine,where the apparatus preferably includes a vacuum pump, air flowregulators connected to outlets of the receivers, with the air flowregulators preferably being vertically oriented for vertical flow of airdrawn by suction therethrough, a first conduit connecting the air flowregulators to a suction head of the vacuum pump and a second conduitconnecting the granular material or supply to the receivers. In thisapparatus aspect of the invention, suction created by operation of thevacuum pump preferably draws granular plastic resin or other materialgranules from the supply of granular material into the receivers throughthe second conduit, and also preferably draws air from the secondconduit through the receivers, the air regulators, and the firstconduit. In this second embodiment, at least one of the air flowregulators preferably consists of a tube, a tubular segment within thetube that is moveable in the axial vertical direction, a plate extendingat least partially across the interior of the tube for contacting themoveable tubular segment and defining a limit of vertical travel of themoveable tubular segment, a sail connected to the moveable tubularsegment and being moveable therewith within the tube, and a baffleconnected to and within the tube defining a second limit of verticaltravel of the moveable tubular segment, where the moveable tubularsegment is in sliding, telescoping engagement with the tubular portionof the baffle and the baffle directs air flow within the tube into thetubular segment. The moveable tubular segment moves unitarily with thesail in response to vertical air flow through the tube contacting thesail.

While the foregoing summarizes the invention and the manner ofpracticing it in a manner that one of skill in the art can practice theinvention, it is to be understood that the foregoing summary of theinvention is only a summary and that the invention has aspects broaderthan those recited. The invention may be implemented in embodimentsother than those disclosed herein and may be practiced using apparatusother than that disclosed herein. It is further to be understood thatthe drawings are attached for purposes of explanation only and that oneof skill in the art, upon reading the foregoing description and summaryof the invention and looking at the drawings, might contemplatealternate means of practice of the invention. All of such alternatemeans are deemed to be within the scope of the invention so long asthose alternate means achieve essentially the same result in essentiallythe same way as the invention and are functionally related to thefunction of this invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of a resin or other granularmaterial delivery system with a single air flow regulator in accordancewith aspects of the invention.

FIG. 2 is a schematic representation of a resin or other granularmaterial delivery system with a plurality of air flow regulators inaccordance with aspects of this invention.

FIG. 3 is an isometric view of the exterior of an air flow regulatorportion of apparatus for pneumatically conveying granular plastic resinor other material granules in accordance with aspects of the invention.

FIG. 4 is a front elevation of the air flow regulator illustrated inFIG. 3.

FIG. 5 is an isometric sectional view of the air flow regulatorillustrated in FIGS. 3 and 4, with the section taken at arrows 3-3 inFIG. 4.

FIG. 6 is a sectional view in elevation of the air flow regulatorillustrated in FIGS. 3 and 5, with the section taken at lines and arrows3-3 in FIG. 4, with air flow through the air flow regulator beingdepicted in FIG. 6 by curved dark arrows.

FIG. 7 is a sectional view in elevation similar to FIG. 6 but with theair flow regulator internal parts in position whereby there is no airentering the air flow regulator and hence there is no air flow upwardlythrough the air flow regulator, in contrast to such air flow being shownin FIG. 6.

FIG. 8 is a sectional view in elevation similar to FIGS. 6 and 7 butwith the air flow regulator internal parts in position where there is anexcessive amount of air attempting to enter the air flow regulator butthere is no air flow upwardly through the air flow regulator due to theair flow regulator valve having moved to block air flow upwardly throughthe air flow regulator, in contrast to upward air flow through the airflow regulator as shown in FIG. 4.

FIG. 9 is an exploded isometric view of the air flow regulatorillustrated in FIGS. 3 through 8.

FIG. 10 is an isometric view of the movable portion of the air flowregulator illustrated in FIGS. 3 through 9.

FIG. 11 is a sectional view of the air flow regulator similar to FIGS.6, 7 and 8, illustrating an alternate construction of the baffle portionof the air flow regulator.

FIG. 12 is sectional view of the air flow regulator similar to FIGS. 6,7, and 11, illustrating a second alternate construction of the baffleportion of the air flow regulator.

DETAILED DESCRIPTION OF THE OF THE INVENTION

In this application, unless otherwise apparent from the context it is tobe understood that the use of the term “vacuum” means “air at slightlybelow atmospheric pressure.” The vacuum (meaning air slightly belowatmospheric pressure) provides a suction effect that is used to drawgranular plastic resin or other granular material out of a supply and toconvey that resin or other granular material through various conduits toreceivers where the resin or other granular material can be temporarilystored before being molded, extruded, or otherwise processed. Hence, inthis application it is useful for the reader mentally to equate the term“vacuum” with the term “suction”.

Referring to the drawings in general and to FIG. 1 in particular,apparatus for conveying granular plastic resin material or othergranular material from the supply to receivers that retain and dispensethe resin or other material granules when needed by a process machine isillustrated in FIG. 1. The apparatus, which is designated generally 88in FIG. 1, preferably includes a vacuum pump designated generally 92 andshown schematically in FIG. 1. The vacuum pump preferably includes avacuum pump suction head 93 also shown schematically in FIG. 1.Connected to the vacuum pump suction head 93 is an airflow regulator 30shown only in schematic form in FIG. 1, but shown in detail in FIGS. 3through 12. Airflow regulator 30 receives vacuum drawn by vacuum pump 92through vacuum drawing conduit 100.

Vacuum drawing conduit 100 is connected to a plurality of receivers 16,each of which receives, retains and dispenses, as needed, granularplastic resin material or other granular material to a process machine,such as a granulator, a blender, an extruder, or a molding press, aslocated preferably below a receiver 16. The process machines are notillustrated in FIG. 1 to enhance the clarity of the drawing.

Further illustrated in FIG. 1 is a hopper 18 for storage of granularplastic resin material or other granular materials therein and a resinconveying conduit 98, which serves to draw resin from hopper 18 and todeliver the granular material through resin conveying conduit 98 to therespective receivers as vacuum is drawn by the vacuum pump, with vacuumpropagating through air flow regulator 30, vacuum drawing conduit 100,the various receivers 16, and resin conveying conduit 98, back to hopper18.

FIG. 2 shows an alternate embodiment of the granular material conveyingsystem where this alternate embodiment of the conveying system has beendesignated 88A. FIG. 2, as in FIG. 1, depicts a vacuum pump 92 shown inschematic form having a vacuum pump suction head 93 also depicted inschematic form. In the alternate embodiment illustrated in FIG. 2,vacuum drawing conduit 100 leads directly into and communicates withvacuum pump suction head 93. In the embodiment illustrated in FIG. 2, anair flow regulator 30 is provided for each receiver 16, with the airflow regulator 30 for a respective receiver 16 being located in aportion of a connection conduit 102 that connects a respective receiverto vacuum drawing conduit 100. In FIG. 2, each air flow regulator 30 isdepicted in a vertical orientation, just as airflow regulator 30 isdepicted in a vertical orientation in FIG. 1. Each receiver is connectedby connection conduit 102 to vacuum drawing conduit 100 with air flowregulator 30 preferably forming a portion of connection conduit 102.

In FIG. 2, as in FIG. 1, a first conduit 98 serves to convey granularplastic resin or other material granules from hopper 18 to therespective receivers in response to vacuum drawn by vacuum pump 92 asthat vacuum propagates from vacuum pump 92 through second conduit 100,connection conduits 102, receivers 16, and granular material conveyingconduit 98, to hopper 18.

During operation of the granular material conveying systems shownschematically in FIGS. 1 and 2, upon actuation of vacuum pump 92, avacuum preferably is drawn at vacuum pump suction head 93. This vacuum,as it propagates back to hopper 18, serves to draw granular material outof hopper 18 and into the respective receivers 16. In the embodimentillustrated in FIG. 2, individual air flow regulators 30 limit thesuction or vacuum drawn by vacuum pump 92 through a given associatedreceiver 16. In the embodiment illustrated in FIG. 1, a single air flowregulator 30 limits the vacuum drawn through all of receivers 16 forminga portion of the granular resin or other granular material conveyingsystem illustrated in FIG. 1.

Referring to FIGS. 1 and 2, the air flow regulator 30 portion of thegranular material delivery system is preferably in the general form of asubstantially vertically oriented tube, preferably having inlet andoutlet ends 54, 56 respectively. The preferably tubular character of airflow regulator 30 is apparent from FIGS. 3 through 8, where air flowregulator 30 preferably includes a vertically oriented exterior tube 32,with open-end caps 58, 60 defining and providing open inlet and outletends 54, 56 respectively. End caps 58, 60 are open, preferably ofgenerally cylindrical configuration, and are configured to fit closelyabout vertically oriented tube 32 so as to provide a substantially airtight fit between end caps 54, 56 and tube 32.

As illustrated in FIG. 5, air flow regulator 30 preferably includes,within vertically oriented exterior tube 32, a horizontally positionedplate 46, which is oriented perpendicularly to the axis of tube 32.Plate 46 is preferably configured as a circular disk of lesser diameterthan the inner diameter of vertically oriented tube 32, with plate 46further preferably including three legs extending outwardly from thecircular interior disk portion of plate 46. Legs of plate 46 aredesignated 62 in FIG. 9, while the circular interior portion of plate 46is designated 64 in FIG. 9. Plate 46 is secured to the interior ofvertically oriented outer tube 32 by attachment of legs 62 to theinterior surface of tube 32. Any suitable means of attachment, such asby welding, adhesive, mechanical screws, or end portions of legs 62defining tabs fitting into slots within tube 32 as shown in FIG. 5, maybe used.

As best shown in FIGS. 5, 6, and 7, a baffle 52 is positioned withinvertically oriented outer tube 32, below plate 46. Baffle 52 has a lowerconical portion 66 and an upper cylindrical portion 44, with cylindricalportion 44 defining a fixed internal tubular segment of air flowregulator 30. Baffle 52 is preferably retained in position by a pair ofscrews designated 68, 70 respectively. Baffle 52 preferably rests onscrew 68. Screw 70 preferably fits against the fixed internal tubularsegment 44 portion of baffle 52 to secure baffle 52 in position withinvertically oriented external tube 32. Lateral force applied by screw 70in a direction perpendicular to the axis of vertically oriented externaltube 32, with screw 70 in contact with fixed internal tubular segment44, serves to effectively retain baffle 52 against movement withinvertically oriented external tube 32.

The upper portion of baffle 52, defining fixed internal tubular segment44, is adapted for sliding, preferably telescopic engagement with andmovement therealong by movable tubular segment 42. Fixed to movabletubular segment 42 is a first strut 48 preferably extendingtransversally across the upper portion of movable tubular segment 42 andpreferably secured at either end to movable tubular segment 42, asillustrated in FIG. 10. Preferably extending downwardly from first strut48 is a second strut 50, preferably secured to first strut 48 andpreferably also to a sail 34, as illustrated in FIG. 10 and in FIGS. 5,6, 7, 8 and 9.

Movable sail 34 is preferably planar and positioned fixedly on secondstrut 50 to remain perpendicular with respect to the axis of verticallyoriented outer tube 32. Movable sail 34 is preferably of generallytriangular configuration, as best illustrated in FIGS. 9 and 10, withthe sides of the triangle curving slightly inwardly. The curved edges 72of movable sail 34 converge and terminate to form small rectangularlyshaped extremities of sail 34, which are designated 76 in FIG. 9.

Movable sail 34 is positioned within generally vertically oriented outertube 32 so that rectangular extremities 76 are closely adjacent to butdo not contact the inner surface of preferably vertically oriented outertube 32, so long as sail 34 moves vertically up and down withinpreferably vertically oriented external tube 32. The rectangular shapeof extremities 76 with their outwardly facing preferably planar surfaceassures minimal friction and consequent minimal resistance to movementof movable sail 34 in the event one of rectangular extremities 76contacts the interior surface of vertically oriented tube 32, shouldsail 34 for some reason move laterally, or otherwise, and become skew tothe vertical axis of tube 32.

Movable internal tubular segment 42 is telescopically movable, unitarilywith sail 34, relative to and along fixed internal tubular segment 44. Alower limit of movement of movable tubular segment 42 is illustrated inFIG. 7, where the first strut portion 48 of movable tubular segment 42(shown in FIG. 10) rests on the upper circular edge of fixed internaltubular segment 44. This is the condition when no air is flowing ordrawn through the air flow regulator 30 and gravity causes sail 34together with movable internal tubular segment 42 to drop, with firststrut 48 coming to rest on the upper circular edge of fixed tubularsegment 44.

When air is flowing through air flow regulator 30, as illustratedgenerally in FIG. 6, the moving air pushes against movable sail 34,moving it upwardly. Movable internal tubular segment 42 moves upwardlyunitarily with sail 34 due to the fixed connection of movable tubularsegment 42 and movable sail 34 made via first and second struts 48, 50,as illustrated in FIGS. 5, 6, 7, 9, and 10.

If air flow upwardly through air flow regulator 30 reaches an extremelevel, above an acceptable level of operation of the granular materialdelivery system of which air flow regulator 30 is a part, the excessiveforce (resulting from the high volume of air flow contacting sail 34)pushes sail 34 upwardly to the point that upper annular edge 78 ofmovable internal tubular segment 42 contacts plate 46. In thiscondition, which is illustrated in FIG. 8, no air can pass between theupper annular edge 78 of movable tubular segment 42 and flow limitinghorizontal plate 46, and air flow stops.

Once air flow stops through vertically oriented outer tube 32, gravitypulling downwardly on sail 34, connected movable internal tubularsegment 42, and connected first and second struts 48, 50, causes theseparts, which may preferably be fabricated together as a single integralassembly as shown in FIG. 8, to move downwardly, thereby againpermitting air flow upwardly through air flow regulator 30 as depictedgenerally in FIG. 6. Consequently, air flow regulator 30 isself-regulating in that when air flow is too high, the force of airmoving or impinging on sail 34 pushes movable internal tubular segment42 upwardly until upper annular edge 78 of movable tubular segment 42contacts plate 46 and no air can then escape upwardly between the upperannular edge 78 of movable tubular segment 42 and plate 46. This stopsair flow through flow regulator 30 until downward movement of sail 34together with movable internal tubular segment 42 moves upper annularedge 78 of movable tubular segment 42 away from plate 46, againpermitting air to flow through the upper extremity of movable tubularsegment 42, with air passing between upper annular edge 78 of movableinternal tubular segment 42 and flow limiting horizontal plate 46, andthen escaping through upper outlet end 56 of air flow regulator 30.

With the self-regulating characteristic of air flow regulator 30, theassembly consisting of movable internal tubular segment 42, first andsecond struts 48, 50 and sail 34 may oscillate somewhat about theposition at which air flow drawn by suction is at the desired level, asthe speed of the vacuum pump drawing air through flow regulator 30varies, and hence the flow varies in cubic feet per minute of air drawn.

Desirably, ends of first strut 48, which is depicted as beinghorizontally disposed in the drawings, are mounted in movable tubularsegment 42 in movable fashion such that first strut 48 can moveslightly, rotationally, relative to movable internal segment 42. This isto provide a small amount of “play” in the event movable sail 34 andsecond strut 50, which is vertically oriented and connected to movablesail 34, become skew with respect to the vertical axis of verticallyoriented exterior tube 32. Should this occur, the movable characteristicof first strut 48, being slightly rotatable relative to movable internaltubular segment 42, effectively precludes movable internal tubularsegment 42 from binding with respect to fixed internal tubular segment44 and thereby being restricted from what would otherwise be freelytelescoping movement of movable internal tubular segment 42 relative tofixed internal tubular segment 44.

Desirably first strut 48 is rotatable relative to movable internaltubular segment 42, to provide maximum freedom of vertical motion ofmovable internal tubular segment 42 in the event movable sail 34 becomesskew to the axis of vertically oriented exterior tube 32, withconsequent frictional force restricting vertical movement of movablesail 34.

Baffle 52 preferably includes two portions, the upper portion preferablybeing defined by fixed internal tubular segment 44 and a lower portionpreferably being defined by conical portion 66 of baffle 52. A loweredge of baffle 52 is circular and is designated 84 in the drawings.Circular edge 84 fits closely against the annular interior wall ofvertically oriented exterior tube 32 so that all air passing upwardlythrough air flow regulator 30, namely through preferably verticallyoriented exterior tube 32, is constrained to flow through the interiorof baffle 52. The tight fitting of the circular lower edge of baffle 52against the interior wall of vertically oriented exterior tube 32 forcesall air entering flow regulator 30 from the bottom to flow through theinterior of baffle 52, flowing upwardly through lower conical portion 66of baffle 52.

The air then flows further upwardly through the interior of fixedinternal tubular segment 44. Thereafter, if movable internal tubularsegment 42 is spaced away from flow limiting horizontal plate 46, airflows along the surface of movable internal tubular segment 42, passingthe upper annular edge 78 of movable internal tubular segment 42; airthen flows around the space between edge 82 of flow limiting horizontalplate 46 and the interior annular wall of vertically oriented exteriortube 32. The air then flows out of air flow regulator 30 via open outletend 56 formed in end cap 60.

In an alternate embodiment of the air flow regulator, baffle 52 may beconstructed from two pieces that fit closely together, with the twopieces being in facing contact in the area where they define fixedinternal tubular segment 44, but diverging one from another in the areawhere they define conical portion 66 of baffle 52. As illustrated inFIG. 12, the two portions of baffle 52 are designated “66A” and “66W”where they diverge, with baffle portion 66A serving to channel air flowupwardly through vertically oriented exterior tube 32 into fixedinternal tubular segment portion 44 of baffle 52. The space between thelower parts of baffle portions 66A and 66B is filled with a fillermaterial 86 to provide additional assurance that all air enteringvertically oriented exterior tube 32 from the bottom flows through fixedinternal tubular segment 44 and on through movable internal tubularsegment 42, and does not pass around the edge of baffle 52, namelybetween baffle 52 and the interior surface of vertically orientedexterior tube 32. Filler material 86 provides additional structuralrigidity for flow regulator 30.

In another alternative environment of the air flow regulator, baffle 52is one single piece, preferably molded plastic, as illustrated in FIG.11, where baffle 52 is designated 52B to distinguish it from the baffleconstruction illustrated in FIG. 12 and the baffle constructionillustrated in the other drawing figures. In the baffle constructionillustrated in FIG. 11, the one piece construction means there is noneed or space for any filler material. The baffle constructionillustrated in FIGS. 3 through 10 is preferred.

The assembly illustrated in FIG. 10 comprising the moveable internaltubular segment 42, first strut 48, second strut 50 and moveable sail 34may preferably be constructed as a single piece or several pieces asrequired. The assembly of moveable internal segment 42, first and secondstruts, 48, 50 and moveable sail 34 is referred to as a “sail assembly.”It is not required that first and second struts 48, 50 be separatepieces; they may preferably be fabricated as a single piece.Additionally, second strut 50, which has been illustrated as a machinescrew in FIGS. 9 and 10, need not be a machine screw. Any suitablestructure can be used for second strut 50 and it is particularlydesirable to fabricate first and second struts 48 and 50 from a singlepiece of plastic or metal, by molding, by machining, or by welding, orby otherwise fastening two pieces together. Similarly with the hex nut,which is unnumbered in FIG. 10 and illustrated there, any other suitablemeans for attachment of the second strut or a vertical portion of astrut assembly to moveable sail 34 may be used.

Air flow regulator 30 preferably contains no springs. Air flow regulator30 preferably contains no sensors to provide feedback to a controldevice; no sensors are needed because flow regulator 30 isself-regulating. Air flow regulator 30 preferably includes a tubularvalve, closing against a flat surface, where the tubular valve isdefined by movable internal tubular segment 42 closing against flowlimiting horizontal plate 46. Movable internal tubular segment 42 is inthe form of an open-ended cylinder and is connected to a plate in theform of movable sail 34 to move movable tubular segment 42 against flowlimiting horizontal plate 46. Air flow regulator 30 uses gravity aloneto open the valve defined by the assembly of movable internal tubularsegment 42, movable sail 34, and the connecting structure therebetween.

In the air flow regulator illustrated in FIGS. 3 through 12, the movableinternal tubular segment 42 is preferably made with a very thin wall,preferably from metal tubing, where the wall is preferably less than1/32 inch in thickness.

Air flow regulator 30 functions equally well with a vacuum pump drawingair through air flow regulator 30 from bottom to top by application ofvacuum to outlet end 56 as depicted generally in FIGS. 1 and 2, or byair being supplied under positive pressure at inlet end 54 for passageupwardly through air flow regulator 30.

While the invention and the modes of operation have been describedclearly and in more than sufficient detail that one of skill in the artmay practice the invention using the teachings of the instantapplication, and while the claims appended hereto are clear and conciseand find full support in the foregoing specification, the invention isnot limited to the embodiments described in the foregoing specificationor to the literal language of the appended claims. The invention furtherembraces components, assemblies and methods not disclosed herein butwhich would perform substantially the same function in substantially thesame way to achieve the same result as the apparatus and methods thatare the subject of the appended claims, all in accordance with thespirit of the invention.

In the claims appended hereto, the term “comprising” is to be understoodas meaning “including, but not limited to” while the phrase “consistingof” is to be understood a meaning “having only and no more”. The phrase“consisting essentially of” is to be understood to mean the specified,recited elements, materials or steps, as well as those that do notmaterially affect the basic and novel characteristics of the claimedinvention. See In re Herz, 537 F.2d 549; 190 USPQ 461 (CCPA 1976); 2111Manual of Patent Examining Procedure, Ninth Edition, Revision July 2015,Last Revised November 2015.

The following is claimed:
 1. In a method using a vacuum pump forpneumatically conveying granular resin from a resin supply to aplurality of standalone self-contained receivers, such conveyance beingpowered by a single vacuum pump connected to all of the receivers via aconveyance conduit, all of the receivers being connected to the supplyby a supply conduit, the improvement in controlling conveyance ofgranular resin from the supply to the receivers without use of centralcontrol, comprising: a) positioning a standalone unpowered air flowregulator immediately upstream of the vacuum pump suction inlet; b)drawing vacuum through the air flow regulator from the supply and thereceivers; c) closing the air flow regulator upon air flow drawn by thevacuum pump exceeding a preselected value by positioning a sail portionof the regulator in the air flow entering the regulator, the sail movinga telescoping member of the regulator against a blocking plate portionof the regulator thereby blocking draw of vacuum from the supply throughthe receivers and halting conveyance of granular resin material; and d)opening the air flow regulator upon air flow drawn by the vacuum pumpdropping to at least the preselected value thereby permitting resumptionof granular resin material conveyance.
 2. A method for conveyinggranular resin plastic material from a supply to receivers, comprising:a) providing a vacuum pump; b) connecting a self-contained air flowregulator, the regulator a telescoping member movable against atransverse blocking plate interior of the regulator, the blocking platebeing connected to a sail positioned within air flow within theregulator, the regulator maintaining flow drawn by the vacuum pump to apreselected value, regulator to a suction head of the vacuum pump, theflow regulator blocking flow when the preselected value is exceeded andblocking any flow if the vacuum pump fails and vacuum draw ceases; c)connected the receivers to the air flow regulator, each of the receiversbeing self-contained without connection to or receipt of electricalsignals; d) connecting a supply of granular plastic resin material tothe receivers; and e) actuating the vacuum pump, thereby drawing vacuumfrom the supply via a conduit to the receivers and from the receiversvia a second conduit to the pump; the vacuum drawing the granularplastic material from the supply to the receivers.
 3. In a method usinga vacuum pump for pneumatically conveying granular resin from a resinsupply to a plurality of standalone self-contained receivers, suchconveyance being powered by a single vacuum pump connected to all of thereceivers via a conveyance conduit, all of the receivers being connectedto the supply by a supply conduit, the improvement in controllingconveyance of granular resin from the supply to the receivers withoutuse of central control, comprising: a) positioning a standaloneunpowered air flow regulator between each receiver and the conveyanceconduit; b) drawing vacuum through the air flow regulators from thesupply and the receivers; c) close any of the air flow regulators uponair flow drawn by the vacuum pump and experienced by a given air flowregulator exceeding a preselected value by positioning a sail portion ofthe regulator in the air flow entering the regulator, the sail moving atelescoping member of the regulator against a blocking plate portion ofthe regulator thereby blocking draw of vacuum from the supply throughthe receivers and halting conveyance of granular resin material; and d)opening the air flow regulator upon air flow drawn by the vacuum pumpdropping to at least the preselected value thereby permitting resumptionof granular resin material conveyance through the regulator.
 4. Themethod of claim 1 wherein the regulator comprises a telescoping membermovable against a transverse blocking plate interior of the regulator,the blocking plate being connected to a sail positioned within air flowwithin the regulator, the regulator maintaining flow drawn by the vacuumpump to a preselected value.